Monolithic Composite Beam Lumber Frame Construction

ABSTRACT

A disclosed building frame construction includes a preformed beam configured to define a plug on a first end and a receptacle of the plug on a second end and multiple holes defined there through, wherein the plug of a first preformed beam and the receptacle of a second preformed beam are configured to interlock and self-align in a first static compression in a plane of the first and second ends. The disclosure also includes a tension mechanism configured to extend through one hole of the plurality of holes and put a plurality of stacked preformed beams in a second static compression orthogonal to the plane of the first and second ends, wherein an overlay of the holes of the plurality of stacked preformed beams define alternating abutting and overlapping layers for a laminate construction in the first and the second compression.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the priority date of earlier filed U.S. Provisional Patent Application Ser. No. 63/345,586 titled ‘Monolithic Composite Beam Construction,’ filed May 25, 2022 by Keith A. Langenbeck, and 63/442,818 titled ‘Lumber Frame Construction,’ filed Feb. 2, 2023 by Keith A. Langenbeck, both incorporated herein by reference in respective entirety.

SUMMARY OF THE INVENTION

A disclosed building frame construction includes a preformed beam configured to define a plug on a first end and a receptacle of the plug on a second end and multiple holes defined there through, wherein the plug of a first preformed beam and the receptacle of a second preformed beam are configured to interlock and self-align in a first static compression in a plane of the first and second ends. The disclosure also includes tension mechanisms configured to extend through one hole of the plurality of holes and put a plurality of stacked preformed beams in a second static compression orthogonal to the plane of the first and second ends, wherein an overlay of the holes of the plurality of stacked preformed beams define alternating abutting and overlapping layers for a laminate construction in the first and the second compression.

Other aspects and advantages of embodiments of the disclosure will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrated by way of example of the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts the various composite beam pieces used to complete the courses of shorter end wall beam and longer side wall beams of a dwelling in accordance with an embodiment of the present disclosure

FIG. 2 depicts that holes create a vertical passage through the vertically stacked courses of side wall and end wall allowing for cables to be anchored to the concrete slab underneath the small home in accordance with an embodiment of the present disclosure.

FIG. 3 depicts an end view of the small home with certain components of the roof seen as removed or exploded for clarification in accordance with an embodiment of the present disclosure.

FIG. 4 depicts the cross section/profile and configuration of various profiles of beam members used to construct all of the interior and exterior walls of a home or dwelling in accordance with an embodiment of the present disclosure.

FIG. 5A depicts a laid flat beam member with its major axis of an end cross section in a vertical/up-down orientation with two sets of four dowel pin holes and a center hole for a tension mechanism to pass through in accordance with an embodiment of the present disclosure

FIG. 5B depicts a laid flat beam member with its major axis in a vertical/up-down orientation with one set of four dowel pin holes in accordance with an embodiment of the present disclosure.

FIG. 5C depicts a laid flat beam member with its major axis of an end cross section in a vertical/up-down orientation with two sets of four dowel pin holes and a center hole for a tension mechanism in accordance with an embodiment of the present disclosure.

FIG. 6A illustrates an exploded and slightly different wider version of laid flat beam members in accordance with an embodiment of the present disclosure.

FIG. 6B illustrates an assembled and slightly different wider version of laid flat beam members in accordance with an embodiment of the present disclosure.

FIG. 7 depicts alternative male/female rods as the tension mechanism in accordance with an embodiment of the present disclosure.

FIG. 8 illustrates three different partial or fully recessed, subsurface or flush mounted sliding doors employed for interior use in accordance with an embodiment of the present disclosure.

FIG. 9 illustrates a plan view of a bathroom along with an elevation view entering the bathroom through a sliding door in accordance with an embodiment of the present disclosure.

FIG. 10 depicts an elevation view of stacked wall members with electrical conduit/wiring and plumbing partially or fully recessed, flush or subsurface mounted throughout the dwelling in accordance with an embodiment of the disclosure.

Throughout the description, similar or same reference numbers may be used to identify similar or same elements in the several embodiments and drawings. Although specific embodiments of the invention have been illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the invention is to be defined by the claims appended hereto and their equivalents.

DETAILED DESCRIPTION

Reference will now be made to exemplary embodiments illustrated in the drawings and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Alterations and further modifications of the inventive features illustrated herein and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

This application discloses a unique method for assembling structures such as homes and the like. The description and drawings of this application concern a small personal dwelling but are not limited to that use or application. A unique aspect of this construction is a single profile beam of the same material type such as foamed composite or other material used throughout to complete the dwelling. One of the trade names anticipated for small homes constructed with this system is Hearthstone Homes™.

An example of the composite material type to be used would be an extruded or cast or molded foamed polyurethane as the primary ingredient combined with small particle minerals, such as coal ash, gypsum waste, ground municipal waste glass and etcetera as a filler. Additional ingredients anticipated are reinforcing fibers, small percentage graphene and other amendments to increase strength, durability and functional performance. Other primary materials such as foamed polyethylene are anticipated as well.

Unique to this construction style is the profile and size of the beam that enable it to be the sole building member used to construct the home or dwelling. In this example the composite beam profile is 6″ wide by 12″ high. The length of the composite beams varies as well as the specific function the different members provide. The side and end walls are composed of the 6″ by 12″ composite member profile. The roof beams and roof panels are composed of the same 6″ by 12″ composite beam profile.

Although not a limitation or requirement, this disclosure illustrates a small home 100 of approximately 18′ in width and 30′ in length. The lengths, function and finished shape of the different composite member profile pieces are connected and integrated with certain fasteners, bracketry and guides to complete the structure. The composite beam pieces are machined in such a way that the various building members interlock and self-align during the assembly process.

FIG. 1 illustrates the various composite beam pieces used to complete the courses of shorter end wall beam 120 and longer side wall beams 150 of dwelling 100 in accordance with an embodiment of the present disclosure. In this illustration, end wall beam 120 is composed of a single piece with lower cutouts 122 and obround receptacles 126 for overlapping and aligning with the upper cut out 132 and obround plugs 136 ends of side walls 150. The major axis of obround receptacles 126 of end wall beam 120 is perpendicular to the major axis of end wall beam 120.

Each course of side wall beams 150 are comprised of partial side wall beam 130 members and one of partial side wall beam 140. Partial side wall beam 130 has upper cuts 132 and obround plugs 136 that overlap and align with lower cutouts 122, obround receptacles 126, lower cutouts 142 and obround receptacles 146. The obround receptacles 146 are parallel to the major axis of partial side wall beam 140. Different than a cylindrical plug and receptacle method of engagement, the various obround plugs and receptacles prevent the rotation of side wall beam and end wall beam members once engaged. Also seen in FIG. 1 are vertical holes 60 penetrating down through wall beams.

FIG. 2 illustrates that holes 60 create a vertical passage through the vertically stacked courses of side wall 150 and end wall 120 allowing for tension mechanism such as cables 70 to be anchored to the concrete slab 40 underneath the small home 100 in accordance with an embodiment of the present disclosure. When tightened these cables 70 put all of the walls of the small home 100 in compression and secured to the slab 40. Within the holes and between adjacent vertical courses of wall beams are pipe segments 80. Pipe segments 80 insert at least partially and align the vertically stacked beam members that comprise the four walls of the small house 100.

The roof 300 of small house 100 is comprised of different configurations of the same beam profile. Roof beams 335 are located at each end of the small house. Roof beams 330 are located between roof beams 335 and throughout the rest of the roof 300 structure. Roof panels 320 and 340 are located between roof beams 330 and 335 completing the roof structure. Roof beams 330 and 335 connect with wall beams 230 and 240 at notched and angled surfaces 234 and 244.

FIG. 3 illustrates an end view of the small home 100 with certain components of the roof 300 seen as removed or exploded for clarification in accordance with an embodiment of the present disclosure. Side wall beams 130 and 230 are illustrated in stacked, overlap configuration with end wall beams 120. Above the uppermost end wall beam 120 are modified end wall beams 221, 223, 225, 227 and 229, each with its distal ends machined to correspond with the slope of roof. Modified end wall beams 221, 223, 225, 227, and 229 are overlapped by roof beams 330. Roof beams 330 and 335 have notched and angled surfaces 304 that allow roof beams 330 and 335 to fit within and conformally match with notched and angled surfaces 234 and 244 when roof 300 is assembled.

Modified end wall beams 221, 223, 225, 227, 229 have holes 222 that allow through bolt connection with the adjacent roof beams 330. Formed or flat steel brackets 400 with holes or slots 402 are used in conjunction with conventional threaded nuts and bolts to mechanical tie roof beams 330 and 335 with holes 332 to modified end wall members 221, 223, 225, 227, 229. Angled steel bracket 500 with holes or slots 502 are used in conjunction with conventional threaded nuts and bolts to mechanically tie roof beams 330 and 335 with holes 332 to side wall beams 230 and 240 through holes 262, as illustrated in FIG. 2 . At the peak of the roof, one of the flat or formed brackets 400 overlaps and connects opposite roof beams 330 and 335 with conventional threaded nuts and bolts.

Modified end wall beams 221 and 227 have machined flat surfaces to accommodate the cable 70 tensioning system. Roof panels 320 and 340 reside within and between opposing roof beams 330 and 335. The upper surface of roof panels 320 and 340 resides flush with the upper surfaces of roof beams 330 and 335. Roof panels 320 and 340 would be affixed to roof beams 330 and 335 with a uniform, full-coverage exterior adhesive coating to weather seal the roof 300 and add structural integrity to small house 100.

Doors and windows for small home 100 would be cut in after all courses of side walls 150 and end walls 120 have been assembled, after cable 70 system has been pretensioned and before the roof 300 is completed. Although not shown, this disclosure anticipates the use of thin compressive gaskets between vertical end wall 120 courses and side wall 150 courses and the concrete slab 40.

When completed, all walls of the small home 100 will be tensioned to slab 40 or foundation. All roof beams will be through bolt fastened to either an end wall 120 or a side wall 150. No nails, nails plates or screws into the beams are employed throughout the construction. The result is a pre-engineered and pre-manufactured construction system that is robust in the extreme, super-insulated, fire resistant, mold and mildew resistant, quiet, low cost and uses no wood to complete the shell. Once the slab has cured, container(s) of the entire small home 100 components would arrive at the site, be unloaded and fully assembled within days, not weeks and months, while using essentially unskilled labor.

Manufactured beams of the common profile, either extruded or cast, would be machined, cut, drilled, bored and completely prepared at the factory before loading into containers for shipping. This system allows for complete kits of small home 100 to shipped by truck, train or ship to any destination.

This application discloses other unique methods and materials for assembling structures such as homes and the like. The description and drawings of this application describe a small personal dwelling but are not limited to that use or application. A unique aspect of this construction method is the utilization of a single cross section or profile of lumber, whether made of wood, composite wood material or composite synthetic material, laid flat, stacked and used to construct the exterior and interior walls throughout. One of the tradenames anticipated for small homes constructed with this system is Hearthstone Homes©.

An example of the lumber profile/cross section and constituent material would be kiln dried 2×6 (1.5″×5.5″ actual) sourced from pine trees. Another material type would be extruded or cast foamed polyurethane composite of similar cross section and material properties to wood. The polyurethane composite combined with small particle minerals, such as coal ash, gypsum waste, ground municipal waste glass and etcetera as aggregate or filler. Additional ingredients anticipated within synthetic material versions include but are not limited to reinforcing fibers (create grain direction), small percentage graphene and other amendments to increase strength, durability and functional performance. Other primary materials include oriented strand board/lumber made of hemp fiber, bagasse waste fiber from sugar cane and other organic or inorganic fibers combined with binders to fabricate lumber or boards of the desired dimensions and material properties.

Seen in FIG. 4 , the cross section/profile and configuration of various beam members 900 enable a single profile to be used to construct all of the interior and exterior walls of the home or dwelling in accordance with an embodiment of the present disclosure. In this example the member profile is nominal 2″ wide by nominal 6″ high (2×6). Alternate cross sections include nominal 2″ (1.5″ actual)×nominal 8″ (7.5″ actual), actual 2″ actual×actual 6″ and others. The length of the beams varies as well as the specific function of different members. The roof truss systems and roof panels in this representation are anticipated to be light gauge, formed steel but are not a limitation.

Furthermore, FIG. 4 illustrates a small home 1000 approximately 20′ wide and 60′ long with side elevation views 1020 and 1030, end elevation view 1040 and floor plan view 1010. Also seen are bedrooms 1052, bedroom/utility room 1053, bathrooms 1054, closets 1055, living area 1056, kitchen 1058, windows 1062, hinged doors 1064, sliding doors 1070 and other details.

Laid flat beam members 900 would be cut to various lengths and machined to abut, overlap, interlock and self-align with other laid flat beam members 900 during the assembly process onto a finished slab or foundation 800. The connection and integration of the various length, laid flat members 900 anticipates the use of dowel holes and dowel pins, sealing gaskets, glue and tension mechanism to complete the interior and exterior walls.

Attention is now given to further illustrating the stacking and pinning sequence of the bottom three courses of beam members 900 at corner 1015 seen in FIG. 4 . Seen specifically in FIG. 5A, 910 is a laid flat beam member with its with its minor axis of an end cross section in the vertical/up down orientation with two sets of four 860 dowel pin holes and a center hole 870 for a tension cable to pass through in accordance with an embodiment of the present disclosure. 910 and 915 are flat beam members with its major axis of an end cross section in a horizontal/left-right orientation seen with one set of four 860 dowel pin holes. The left end of 915 abuts flush with the right edge of 910. The lower end of 910 is aligned parallel with the lower edge of 915.

Seen in FIG. 5B, 920 is a laid flat beam member with its minor axis of an end cross section in a vertical/up-down orientation with one set of four 860 dowel pin holes in accordance with an embodiment of the present disclosure. 925 is a laid flat beam member with its major axis in a horizontal/left-right orientation seen with two set of four 860 dowel pin holes and a center hole 870 for a tension cable to pass through. 925 overlaps a portion of 910 and 915. The left end of 925 aligns parallel with the left edge of 910 and the left edge of 920. The lower end of 920 abuts the upper edge of 925. The tension cable holes 870 for 910 and 925 align in a concentric relationship. The various dowel pins holes of 910, 915, 920 and 925 align in a concentric relationship.

Dowel pins 800 are nominally the same outside diameter as the inside diameter of dowel pin holes 860. Dowel pins 800 are slightly less in length than the thickness of two laid flat beam members 900 stacked on top of each other. Seen in FIG. 5B, dowel pins 865 are driven flush into top-left and bottom-right diagonal holes of two of the four-hole sets, affixing 925 to 915 and 910 below. Dowel pins 865 are driven flush into top-left and bottom-right diagonal holes of the remaining four-hole set and affixing 920 to 910.

Seen in FIG. 5C, 930 is a laid flat beam member with its minor axis of an end cross section in a vertical/up-down orientation with two sets of four 860 dowel pin holes and a center hole 870 for a tension cable to pass through in accordance with an embodiment of the present disclosure. 935 is a laid flat beam member with its major axis of an end cross section in a horizontal/left-right orientation seen with one set of four 860 dowel pin holes. 930 overlaps a portion of 920 and 925. The lower end of 930 aligns parallel with the lower edge of 935 and the lower edge of 925. The left end of 935 abuts the right edge of 930. The tension cable holes 870 for 930, 925 and 910 align in a concentric relationship. The various dowel pins holes of 930, 935, 920 and 925 align in a concentric relationship.

Dowel pins 867 are driven flush into top-right and bottom-left diagonal holes of two of the four-hole sets, affixing 930 to 925 and 920 below. Dowel pins 867 are driven flush into top-right and bottom-left diagonal holes of the remaining four-hole set and affixing 935 to 925.

Over lapping patterns of concentric dowel pin hole 860 sets filled with dowel pins 800 of laid flat beam members 900 described herein would be repeated to assemble and affix the exterior and interior walls of dwelling 1000.

It is anticipated that continuous gasket material would be sandwiched between the first course of beam members 900 and the foundation 800 to prevent water penetration. Gasket material might also be used between other stacked beam members 900.

Further, the interface surfaces between stacked beam members comprising the exterior and interior walls could be coated with glue. Tension cables 820, not shown for ease of illustration, would first be anchored to the foundation 800 at locations corresponding with tension cable holes 870 throughout the assembled walls of dwelling 1000. Tension cables 820 would extend past the uppermost beam members 900 and be equipped with fasteners and related components. Applying tension to cables 820 throughout the interior and exterior walls would compress the assembled exterior and interior walls of the dwelling 1000 into a glue laminated, integrated structure increasing structural rigidity, durability and strength to sustain severe environmental conditions.

FIG. 6A illustrates an exploded and slightly different wider version of laid flat beam members 900 of FIG. 4 in accordance with an embodiment of the present disclosure. Plug elements 903 of laid flat beam member 955 corresponds to receptacle elements 901 of laid flat beam member 950 along the sides and ends of laid flat various beam members. When plug elements 903 are fully engaged within receptacles 901, laid flat beam members are accurately aligned in coaxial and right-angle relationships. Engagement of plug elements 903 within receptacle elements 901 prevent air leakage when beam members are assembled and abutted one to another. Fully engaged, plug and receptacle relationship adds side or wind load strength to the dowel pin connection located throughout the courses of beam members 900 that comprise the walls of small home 1000.

FIG. 6B illustrates an assembled and slightly different wider version of laid flat beam members 900 of FIG. 4 in accordance with an embodiment of the present disclosure. Plug elements 903 of laid flat beam member 955 corresponds to receptacle elements 901 of laid flat beam member 950 along the sides and ends of laid flat various beam members.

FIG. 7 illustrates alternative tension mechanism in accordance with an embodiment of the present disclosure. Tension rods 880 comprise tension cables 820 (not shown) are connected to the foundation 800 at locations corresponding with tension cable holes 870 throughout the assembled walls of dwelling 1000. The completed assembly of tension rods 880 would extend past the uppermost beam members 900 and be equipped with fasteners and related components. The lowermost tension rods 880 would be threaded fully down and over concrete anchor 805 and flush with the concrete foundation 800. When threaded down and over concrete anchor 805, tension rods 880 would be self-standing and long enough to receive several courses of flat beam members 900 before requiring the threaded attachment of the next tension rods 880. Consecutive tension rods 880 are threaded down and flush with the lower mating surface of the tension rods immediately below. Applying tension to tension rods 880 throughout the interior and exterior walls would compress the assembled exterior and interior walls of the dwelling 1000 into a glue laminated, integrated structure increasing structural rigidity, durability and strength to sustain severe environmental conditions. Below window openings and above window and door openings tension mechanism (not depicted) would be slightly different in execution but still effect the compression of the stack flat beam members 900.

FIG. 8 , a section snapshot from FIG. 4 , illustrates three different partial or fully recessed, subsurface or flush mounted sliding doors 1072, 1074 and 1076 employed for interior use in accordance with an embodiment of the present disclosure. As indicated by phantom lines, certain interior wall members 900 would be machined along one edge removing material to allow partial or fully recessed, subsurface or flush mounted sliding doors 1072, 1074 and 1076. Sliding doors 1072, 1074 and 1076 would not be pocket doors. In this representation, sliding door 1072 would be the entrance into bedrooms 1052 and approximately 4′6″ wide. Sliding door 1074 would be the entrance to bedroom 1053, bathrooms 1054 and approximately 4′0″ wide. Sliding door 1076 would be the entrance to bathrooms 1054 from bedroom/utility room 1053, living area 1056 and approximately 2′6″ wide.

FIG. 9 illustrates a plan view 1174 of bathroom 1054 along with an elevation view 1274 entering bathroom 1054 through sliding door 1074 in accordance with an embodiment of the present disclosure.

FIG. 10 is an elevation view of stacked wall members 900 that illustrates electrical conduit/wiring 500 and plumbing 550 partially or fully recessed, flush or subsurface mounted throughout dwelling 1000 in accordance with an embodiment of the present disclosure. Interior surfaces of one or more wall members 900 would be machined along one edge removing material to allow partial or fully recessed, subsurface or flush mounting of electrical conduit/wiring and plumbing.

Factory manufactured beams of the common profile would be machined, cut, drilled, bored and completed before loading into containers for shipping. No nails, nails plates or screws into the beams are employed throughout the construction. The result is a pre-engineered and pre-manufactured construction system that is robust in the extreme.

Wall construction described herein would reduce air leakage, reduce energy consumption, qualify as mass timber sustainable construction, provide precision locations for windows and doors, reduce completion time at the building site, all but eliminate construction site waste, be containerized for domestic and overseas shipment, reduce overall labor costs and reduce total cost. This system allows for complete containerized kits of small home 1000 to be transported by truck, train, plane or ship to virtually any destination.

Although the components herein are described and depicted in a particular order, the order thereof may be altered so that certain advantages or characteristics may be optimized. In another embodiment, instructions or sub-operations of distinct steps may be implemented in an intermittent and/or alternating manner.

Notwithstanding specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the invention is to be defined by the claims and their equivalents. 

What is claimed is:
 1. Abuilding frame construction comprising: a preformed beam configured to define a plug on a first end and a receptacle of the plug on a second end and a plurality of holes defined there through, wherein the plug of a first preformed beam and the receptacle of a second preformed beam are configured to interlock and self-align in a first static compression in a plane of the first and second ends; and a tension mechanism configured to extend through one hole of the plurality of holes and put a plurality of stacked preformed beams in a second static compression orthogonal to the plane of the first and second ends, wherein an overlay of the holes of the plurality of stacked preformed beams define alternating abutting and overlapping layers for a laminate construction in the first and the second compression.
 2. The construction of claim 1, wherein the plugs and receptacles are obround and configured to limit a movement of preformed beam members and a dynamic compression.
 3. The construction of claim 1, wherein each of the first and the second end both comprise a plug and a receptacle.
 4. The construction of claim 1, further comprising a gasket seal between a foundation and a concrete slab and the preformed beam.
 5. The construction of claim 1, further comprising a glue between the plurality of stacked preformed beams.
 6. The construction of claim 1, further comprising dowel pins flushly received in the plurality of holes of stacked preformed beams in a clockwise pattern in the plane.
 7. The construction of claim 1, further comprising dowel pins flushly received in the plurality of holes of stacked performed beams in a counterclockwise pattern in the plane.
 8. The construction of claim 1, wherein the tension mechanism comprise sections of tension rod having a first end female and a second end male.
 9. The construction of claim 1, wherein the plurality of stacked preformed beams in the first and second compression comprise building frame walls.
 10. The construction of claim 1, wherein the plurality of stacked preformed beams in the first and the second compression comprise building frame roofs.
 11. The construction of claim 1 wherein the plug is disposed on a terminal side of the first end.
 12. The construction of claim 1, wherein the receptacle is disposed on a lateral side proximal to the second end.
 13. The construction of claim 1, wherein the first preformed beam and the second preformed beam interlock in an abutting configuration at a right angle.
 14. The construction of claim 1, wherein the receptacle is disposed on a terminal side of the first end.
 15. The construction of claim 1, wherein the first preformed beam and the second preformed beam interlock in an abutting configuration one hundred and eighty degrees to each other.
 16. The construction of claim 1, wherein the alternating abutting and overlapping layers comprise right angle configurations of the plurality of stacked preformed beams.
 17. The construction of claim 1, wherein the alternating abutting and overlapping layers comprise straight inline configurations of the plurality of stacked preformed beams.
 18. The construction of claim 1, wherein at least one of the plurality of holes is/are configured to receive the tension mechanism there through.
 19. The construction of claim 1, wherein the preformed beam comprises an extruded or cast or molded polyurethane primary ingredient.
 20. The construction of claim 1, wherein the preformed beam comprises reinforcing fibers, graphene and other particle material secondary ingredients. 